The challenge of quality in continuous casting processes

As in any process, the laws of nature are at work in the continuous casting of metals. Heat spills down temperature gradients under the watchful eye of Fourier, while molten metal moves in response to inertial and body forces governed by the Navier-Stokes equations. Tensile strains develop in the solidifying shell subject to changing cooling conditions, the constitutive behavior of the metal, compatibility, and the Prandtl-Reuss relations. Solutes segregate as thermodynamics compete with diffusion to create a heterogeneous solid from a homogeneous liquid. The challenge to the process engineer is to harness these laws to continuously cast a metal section that is free of cracks, has minimal macrosegregation, and has the desired shape. Confronted with the demands of production, cost containment, and an educationally challenged workforce, the obstacles are very real. One response to the challenge is to move knowledge to the shop floor, where wealth is created, through expert systems to educate the workforce and through artificial intelligence to make the continuous casting process “smart.” Harnessing knowledge for wealth creation, and profitability, is the real challenge. The Edward DeMille Campbell Memorial Lecture was established in 1926 as an annual lecture in memory of and in recognition of the outstanding scientific contributions to the metallurgical profession by a distinguished educator who was blind for all but two years of his professional life. It recognizes demonstrated ability in metallurgical science and engineering. Dr. J. Keith Brimacombe delivered the 1996 Edward DeMille Campbell Memorial Lecture at the ASM-TMS Meeting in Cincinnati, OH. The written lecture was nearly complete at the time of his untimely passing on December 16, 1997 and has been finished and submitted by his colleague, Professor I.V. Samarasekera. On October 1, 1997, J. Keith Brimacombe was appointed the first President and Chief Executive Officer of the Canada Foundation for Innovation. This enterprise, newly established by the Federal Government of Canada, was provided with one billion dollars of funding with the objective of strengthening the nation’s research infrastructure in universities and hospitals. Sadly, Dr. Brimacombe was able to serve only 3 months of his term and succumbed to a massive heart attack on December 16, 1997, at the age of 54. Dr. Brimacombe held the Alcan Chair in Materials Process Engineering, The Centre for Metallurgical Process Engineering at the University of British Columbia, prior to his appointment with the Canada Foundation for Innovation. He was born in Nova Scotia, raised in Alberta, and received his undergraduate education at UBC, obtaining a B.A.Sc. (Hons.) in 1966. With the support of a Commonwealth Fellowship, he traveled to England and studied under one of the great metallurgical thermochemists of this century, F.D. Richardson, F.R.S., at Imperial College of Science and Technology in the University of London, where he received a Ph.D. in 1970. Subsequently, he was awarded the D.Sc. (Eng.) in 1986 by the University of London and an Honorary Doctorate of Engineering degree in 1994 by the Colorado School of Mines. He returned to the University of British Columbia in 1970 to establish courses and a research program in metallurgical process engineering. He remained at UBC, achieving the rank of Professor in 1979, Stelco Professor of Process Metallurgy (a chair endowed by Stelco) in 1980, Stelco/NSERC Professor (a chair endowed by Stelco and NSERC) in 1985, and the Alcan Chair in 1992. One of the finest metallurgical engineers on the world stage in this century, Dr. Brimacombe pioneered the application of mathematical models and industrial and laboratory measurements, to shed light on complex metallurgical processes spanning both the ferrous and nonferrous industries during his 27 year career at the University of British Columbia. For his groundbreaking research, he earned the reputation of being one of the most innovative intellectual giants in the field, for which he earned global recognition. During his tenure at UBC, he built a large collaborative research group in metallurgical process engineering consisting of about 70 faculty, graduate students, research engineers, and technicians. Much of the research was conducted in close collaboration with Canadian companies such as Stelco, Hatch Associates, Algoma Steel, Western Canada Steel, Sidbec-Dosco, Ivaco, Cominco, Noranda, Inco, Alcan, Domtar, Canadian Liquid Air, and Liquid Carbonic. The thrust of the research was the development and improvement of metallurgical processes, such as continuous casting of steel, flash smelting of lead and copper converting, rotary kilns, and micro-structural engineering of steel and aluminum, and DC casting processes. This body of work led to 300 publications and nine patents as well as two books. In 1985, in cooperation with faculty colleagues, he founded the Centre for Metallurgical Process Engineering at UBC and was named its Director. The purpose of the Centre is to strengthen the interdisciplinary approach to metallurgical process research and to broaden the field of application to materials other than metals. For this body of research, he was awarded the B.C. Science and Engineering Gold Medal (1985) and the Ernest C. Manning Prize (1987) and, before that, the E.W.R. Steacie Memorial Fellowship (1979) from NSERC. He also received the following awards: TMS-AIME Charles Herty Award (1973 and 1987), AMS Marcus A. Grossmann Award (1976), TMS Extractive Metallurgy Science Award (1979, 1987, and 1989), ISS John Chipman Award (1979, 1985, and 1996), TMS Champion H. Mathewson Gold Medal (1980), ISS Robert Woolston Hunt Silver Medal (1980, 1983, and 1993), ASM Henry Marion Howe Medal (1980 and 1985), TMS Extractive Metallurgy Technology Award (1983 and 1991), the Williams Prize of the Metals Society (UK) (1983), the ISS Mechanical Working and Steel Processing Conference Meritorious Award (1986 and 1996), the ASM Canadian Council Lectureship (1986), and the CIM Metallurgical Society Alcan Award (1988). In 1981, he delivered the Arnold Markey Lecture to the Steel Bar Mill Association. In 1987, he was made a Distinguished Member of the Iron and Steel Society and a Fellow of the Royal Society of Canada. In 1988, he became a Fellow of the CIM and, in 1989, he delivered the TMS Extractive Metallurgy Lecture while being awarded Fellowship in TMS. Also in 1989, he was awarded the Izaak Walton Killam Prize for Engineering by the Canada Council, joined the Board of Directors of Sherritt Gordon Ltd., received the Bell Canada Corporate-Higher Education Award and was appointed an Officer of the Order of Canada. In 1990, he received the Meritorious Achievement Award of the Association of Professional Engineers of British Columbia and a UBC Killam Research Prize. In 1992, he was honored with the Commemorative Medal for the 125th Anniversary of Canadian Confederation and, in 1993, delivered the Howe Memorial Lecture of the Iron and Steel Society and became Fellow of the Canadian Academy of Engineering. In 1994, he presented the D.K.C. MacDonald Memorial Lecture; and in 1995, he was the Inland Steel Lecturer at Northwestern University and received the Ablett Prize of the Institute of Materials. In 1996, he delivered the ASM Edward DeMille Campbell Memorial Lecture and, in 1997, received the AIME Distinguished Service, and he was elected a Foreign Associate of the National Academy of Engineering. In June 1997, he received Canada’s highest scientific honor, the Canada Gold Medal in Science and Engineering from the Natural Sciences and Engineering Research Council of Canada. In 1998, Dr. Brimacombe was posthumously awarded the Benjamin Fairless Award by the AIME and the Inco Medal by the CIM at their centennlal celebration. Beyond the quest to generate knowledge and train young people, he was driven by the desire to see the fruits of his research implemented in industry. Not satisfied that publications in peer-reviewed journals are an effective means of reaching out to the shop floor, where knowledge implementation creates wealth, he worked tirelessly at the University-Industry interface to make the transfer of knowledge to industry a reality. A gifted speaker, he was renowned for his ability to translate complex research results to changes that are required to the process for improved quality and/or productivity. Thus, he was sought after by the global metallurgical industry and presented over 50 courses in companies in every continent. A course on continuous casting of steel offered annually in Vancouver, under his directorship, attracted participants from around the world. He seized the opportunities provided by the revolution in computer technology to help further the transfer of knowledge, and since the early 1980s drove the development of user-friendly mathematical models as a means of transferring research results to industry. Brimacombe was also instrumental in developing “smart” systems for the transfer of knowledge and spearheaded the development of an expert system for diagnosing defects in steel billets, which is being marketed commercially. A recent project involving Canadian companies is the development of a “Smart Process,” in which knowledge is made to work in the process through the use of an on-line expert system and sensors. He gave unreservedly of his time to professional societies, which are a vehicle for knowledge transfer and professional development of materials engineers. He was the only professional who was President of the three major societies serving materials engineers in North America: TMS-CIM in Canada in 1985, TMS-AIME in 1993, and ISS-AIME in 1995. His enthusiasm for professional societies was infectious and has led to the initiation of a very dynamic student chapter at UBC. He served on the Killam Research Fellowships Committee of the Canada Council from 1982 to 1985, where he initiated the Killam Prize in Engineering and worked on other committees of the Canadian Council of Professional Engineers, the Science Council of British Columbia, and the Canadian Steel Industry Research Association. He served on the Boards of the ISS and TMS in the United States. He served on numerous committees in these societies, including Joint Commission and Board of Review of Metallurgical Transactions, Book Publishing Committee, Awards Committee, Extractive Metallurgy Sub-committee, Nominating Committee, and Long Range Planning Committee. In 1989, he assumed responsibilities as Founding Chairman of the TMS Extraction and Processing Division, in 1993–4 was TMS President, and in 1994–5 was Founding President of the TMS Foundation. In 1990, he was named as an Eminent Scientist to the Board of Directors of the Ontario Centre for Materials Research. In 1995, he was Chairman of the Science Policy Committee of the Royal Society of Canada and was a member of the National Materials Advisory Board (united States). In 1996, he was elected Vice President of the Academy of Science of the Royal Society of Canada and was appointed to the Board of the United Engineering Trust. He served on the Board of Trustees of the AIME since 1993; had he lived, he would have become President of the AIME in 1999.     

Why materials science and engineering is good for metallurgy

Metallurgy/materials education will continue to evolve to encompass, in an intellectually unified way, the full range of structural and functional materials. Computation, information, and other advanced sciences and technologies will assume increasing roles in materials education, as will distance and continuing education. The advantages of the changes will be many … to the graduates, to emerging industries, and to the traditional metallurgical industries seeking productive, creative young engineers as employees. The need for continuing change in our metallurgy/materials departments is now no less if we are to attract the best young people into our field in the numbers needed and to best serve the needs of industry. Merton C. Flemings received his S.B. degree from MIT in the Department of Metallurgy in 1951. He received his S.M. and Sc.D. degrees, also in Metallurgy, in 1952 and 1954, respectively. From 1954 to 1956, he was employed as Metallurgist at Abex Corporation (Mahwah, NJ), and in 1956 returned to MIT as Assistant Professor. He was appointed Associate Professor in 1961 and Professor in 1969. In 1970, he was appointed Abex Professor of Metallurgy. In 1975, he became Ford Professor of Engineering, and, in 1981, Toyota Professor of Materials Processing. He established and was the first director of the Materials Processing. He established and was the first director of the Materials Processing Center at MIT in 1979. He served as Head, Department of Materials Science and Engineering, from 1982 to 1995 and thereafter returned to full-time teaching and research as Toyota Professor. He was Visiting Professor at Cambridge University in 1971, Tokyo University in 1986, and Ecole des Mines in 1996. In 1999, he was appointed Co-Director of the Singapore-MIT Alliance, a major distance educational and research collaboration among MIT and two Singaporean universities. Professor Flemings’ research and teaching concentrate on engineering fundamentals of materials processing and on innovation of materials processing operations. He is active nationally and internationally in strengthening the field of Materials Science and Engineering and in delineation of new directions for the field. He is a member of the National Academy of Engineering and of the American Academy of Arts and Sciences. He is author or co-author of 300 papers, 26 patents, and 2 books in the fields of solidification science and engineering, foundry technology, and materials processing. He has worked closely with industry and industrial problems throughout his professional career and currently serves on a number of corporate and technical advisory boards. He received the Simpson Gold Medal from the American Foundrymen’s Society in 1961, the Mathewson Gold Medal of TMS in 1969, and the Henry Marion Howe Medal of ASM International in 1973 and became a Fellow, ASM International, in 1976. In 1977, he was awarded the Henri Sainte-Claire Deville Medal by the Societe Francaise de Metallurgie. In October 1978, he received the Albert Sauveur Achievement Award from ASM INTERNATIONAL. In 1980, he received the John Chipman Award from AIME. In 1984, he was elected an honorary member of the Japan Foundrymen’s Society and, in 1985, received the James Douglas Gold Medal from the AIME. The Italian Metallurgical Association awarded him the Luigi Losana Gold Medal in 1986, and he was elected honorary member of The Japan Iron and Steel Institute in 1987. He was elected a TMS Fellow in 1989. In 1990, he received the TMS Leadership Award, and the Henry Marion Howe Medal and delivered the Edward DeMille Campbell Memorial Lecture of ASM INTERNATIONAL. In 1991, he received the Merton C. Flemings Award from Worcester Polytechnic Institute. Sigma Alpha Mu elected him a Distinguished Life Member in 1992. In 1993, he received the TMS 1993 Bruce Chalmers Award and was elected Councillor of the Materials Research Society. He was elected to the ASM INTERNATIONAL Board of Trustees in 1994. He received the Acta Metallurgica J. Herbert Holloman Award in 1997 for “contributions to materials technology that have had major impact on society.” Also in 1997 he was appointed David Turnbull Lecturer of the Materials Research Society for “outstanding contributions to understanding materials phenomena and properties.” He received the Educator Award of TMS in 1999, received the FMS (Federation of Materials Societies) National Materials Advancement Award in late 1999, and delivered the ASM and TMS Distinguished Lecture in Materials and Society in 2000.     

Why materials science and engineering is good for metallurgy

Metallurgy/materials education will continue to evolve to encompass, in an intellectually unified way, the full range of structural and functional materials. Computation, information, and other advanced sciences and technologies will assume increasing roles in materials education, as will distance and continuing education. The advantages of the changes will be many ... to the graduates, to emerging industries, and to the traditional metallurgical industries seeking productive, creative young engineers as employees. The need for continuing change in our metallurgy/materials departments is now no less if we are to attract the best young people into our field in the numbers and to best serve the needs of industry. Merton C. Flemings received his S.B. degree from MIT in the Department of Metallurgy in 1951. He received his S.M. and Sc.D. degrees, also in Metallurgy, in 1952 and 1954, respectively. From 1954 to 1956, he was employed as Metallurgist at Abex Corporation (Mahwah, NJ), and in 1956 returned to MIT as Assistant Professor. He was appointed Associate Professor in 1961 and Professor in 1969. In 1970, he was appointed Abex Professor of Metallurgy. In 1975, he became Ford Professor of Engineering, and, in 1981, Toyota Professor of Materials Processing. He established and was the first director of the Materials Processing Center at MIT in 1979. He served as Head, Department of Materials Science and Engineering, from 1982 to 1995 and thereafter returned to full-time teaching and research as Toyota Professor. He was Visiting Professor at Cambridge University in 1971, Tokyo University in 1986, and Ecole des Mines in 1996. In 1999, he was appointed Co-Director of the Singapore-MIT Alliance, a major distance educational and research collaboration among MIT and two Singaporean universities. Professor Flemings’ research and teaching concentrate on engineering fundamentals of materials processing and on innovation of materials processing operations. He is active nationally and internationally in strengthening the field of Materials Science and Engineering and in delineation of new directions for the field. He is a member of the National Academy of Engineering and of the American Academy of Arts and Sciences. He is author or co-author of 300 papers, 26 patents, and 2 books in the fields of solidification science and engineering, foundry technology, and materials processing. He has worked closely with industry and industrial problems throughout his professional career and currently serves on a number of corporate and technical advisory boards. He received the Simpson Gold Medal from the American Foundrymen’s Society in 1961, the Mathewson Gold Medal of TMS in 1969, and the Henry Marion Howe Medal of ASM International in 1973 and became a Fellow, ASM International, in 1976. In 1977, he was awarded the Henri Sainte-Claire Deville Medal by the Societe Francaise de Metallurgie. In October 1978, he received the Albert Sauveur Achievement Award from ASM INTERNATIONAL. In 1980, he received the John Chipman Award from AIME. In 1984, he was elected an honorary member of the Japan Foundrymen’s Society and, in 1985, received the James Douglas Gold Medal from the AIME. The Italian Metallurgical Association awarded him the Luigi Losana Gold Medal in 1986, and he was elected honorary member of The Japan Iron and Steel Institute in 1987. He was elected a TMS Fellow in 1989. In 1990, he received the TMS Leadership Award, and the Henry Marion Howe Medal and delivered the Edward DeMille Campbell Memorial Lecture of ASM INTERNATIONAL. In 1991, he received the Merton C. Flemings Award from Worcester Polytechnic Institute. Sigma Alpha Mu elected him a Distinguished Life Member in 1992. In 1993, he received the TMS 1993 Bruce Chalmers Award and was elected Councillor of the Materials Research Society. He was elected to the ASM INTERNATIONAL Board of Trustees in 1994. He received the Acta Metallurgica J. Herbert Holloman Award in 1997 for “contributions to materials technology that have had major impact on society.” Also in 1997 he was appointed David Turnbull Lecturer of the Materials Research Society for “outstanding contributions to understanding materials phenomena and properties.” He received the Educator Award of TMS in 1999, received the FMS (Federation of Materials Societies) National Materials Advancement Award in late 1999, and delivered the ASM and TMS Distinguished Lecture in Materials and Society in 2000.     

Research on Sustainable Steelmaking

The international steel community is faced with the challenge of developing processes that will make steel production more sustainable in the future. Specifically, processes that produce less CO₂ and less net waste materials and emissions and that consume less energy are required. This article outlines where energy consumption and CO₂ emissions are high and can be reduced. Reductions can be achieved by incremental improvements to existing processes or by a “break-through innovative process”; both strategies are examined. Since most of the energy consumption and CO₂ generation occur in ironmaking, research in this area is emphasized. Research on controlling the cohesive zone in the blast furnace, improving the final stages of reduction in direct reduction processes, the use of biomass, and other innovative processes for ironmaking are reviewed. In oxygen steelmaking, improved postcombustion (PC) to allow for more scrap melting is examined. Postcombustion and slag foaming in the electric arc furnace (EAF) in order to reduce energy is reviewed. R.J. Fruehan is currently the U. S. Steel University Professor at Carnegie Mellon University. He received his B.S. and Ph.D. degrees from the University of Pennsylvania and was an NSF Scholar at Imperial College, University of London. Dr. Fruehan organized the Center for Iron and Steelmaking Research, and is currently the Co-Director. He was Director of the Sloan Steel Industry Study, which examines the critical issues impacting a company’s competitiveness and involves numerous faculty at several universities from 1992 to 2002. Dr. Fruehan has authored over 250 papers, two books on steelmaking technologies, co-authored a book on managing for competitiveness, and is the holder of six patents. He has received several awards, including the 1970 and 1982 Hunt Medal (AIME), the 1982 and 1991 John Chipman Medal (AIME), 1989 Mathewson Gold Medal (TMS-AIME), the 1993 Albert Sauveur Award (ASM International), the 1976 Gilcrist Medal (Medals Society UK), the 1996 Howe Memorial Lecture (ISS of AIME), the 1999 Benjamin Fairless Award (ISS of AIME), the Brimacombe Prize (ISS, TMS, CSM) (2000), the 2004 Bessemer Gold Medal (Institute of Materials, Minerals & Mining (UK); an IR100 Award for the invention of the oxygen sensor and the TMS Science Award (2008). He is a Distinguished Member of the Iron and Steel Society, an Honorary Member of AIME, an Honorary Member of the Iron and Steel Institute of Japan and served as President of the Iron and Steel Society of AIME from 1990 to 1991. He was elected a Member of the National Academy of Engineers in 1999.     

Modeling of the continuous casting of steel—past,present, and future

This lecture honoring Keith Brimacombe looks over the history, current abilities, and future potential of mathematical models to improve understanding and to help solve practical problems in the continuous casting of steel. Early finite-difference models of solidification, which were pioneered by Keith Brimacombe and his students, form the basis for the online dynamic models used to control spray water flow in a modern slab caster. Computational thermal-stress models, also pioneered by Brimacombe, have led to improved understanding of mold distortion, crack formation, and other phenomena. This has enabled process improvements, such as optimized mold geometry and spray-cooling design. Today, sophisticated models such as transient and multiphase fluid-flow simulations rival water modeling in providing insights into flow-related defects. Heat-flow and stress models have also advanced to yield new insights. As computer power increases and improvements via empirical plant trials become more costly, models will likely play an increasing role in future developments of complex mature processes, such as continuous casting. The Brimacombe Memorial Lectureship was established in 1999 by the Process Technology Division of the Iron & Steel Society to honor Dr. J. Keith Brimacombe’s outstanding accomplishments in the area of process metallurgy, his dedication to the steel industry, and his profound effect on people in the industry; and also to acquaint members, students, and engineers with the many exciting opportunities that exist in the area of process metallurgy and to inspire them to pursue careers in this field. Brian G. Thomas is a professor of mechanical engineering at the University of Illinois and director of the Continuous Casting Consortium. He received his Bachelors of metallurgical engineering from McGill University in 1979 and Ph.D. in metallurgical engineering in 1985 from the University of British Columbia. In between, he worked in the Materials Research Department of Algoma Steel (Sault Ste. Marie, ON). His recent research efforts focus on the development and application of mathematical models of all aspects of the continuous casting of steel and related processes. Dr. Thomas has authored with co-workers over 150 technical publications on his research, which has been recognized with a Presidential Young Investigator Award from NSF, Outstanding Young Manufacturing Engineer Award from SME, Xerox Award for UIUC Faculty research, and more than ten best paper awards from AFS, AIME, ISS, TMS, CIM, and ASM International. He has participated in several short courses to transfer technology to industry, including the annual Brimacombe Continuous Casting Course.     

The search for an economical and environmentally friendly ironmaking process

The scope of the present work is limited to coal-based processes. For environmental and economical considerations, it is desirable to use iron ore concentrates directly without agglomeration and coal directly without coking for ironmaking. The energy efficiency of blast furnace ironmaking, which is improving constantly, is the moving target to overtake. Laboratory data on kinetics and mechanisms of iron oxide reduction in ore/coal mixtures will be reported. These data include the reduction of green pellets of ore/coal mixtures in air atmosphere in a muffle furnace. The advantages of high temperature and tall bed will be discussed. The idea of integration of a rotary hearth furnace with a heat source of very high temperatures such as a smelting reduction vessel mainly for melting and slag-metal reactions will be presented. This article is the main part of the Howe Memorial Lecture delivered by Dr. W-K. Lu at ICSTI’98 and the 57th Ironmaking Conference and 81st Steelmaking Conference in Toronto, ON, Canada. The first half of the Lecture, which is introductory in nature, has been drastically shortened here because these contents have been recently published in five separate papers in 1998 and 1999, co-authored by Lu. The remaining parts are intact and are main messages of the Lecture. Recent development on this subject, under contract with the American Iron and Steel Institute, will be briefly reviewed and included as an Appendix. Wei-Kao Lu is a metallurgical engineer and has been teaching and conducting research at McMaster University Hamilton, ON, Canada since 1965. Born in China, he grew up and went to college in Taiwan. He received his advanced education in the United States at the University of Minnesota before settling in Hamilton to pursue an academic career. At the University of Minnesota, he studied under professors T.L. Joseph and G. Bitsianes and liked the challenge presented by the monster blast furnace, but felt inadequately prepared for the task. His attention, then, was focused on physical chemistry. His interest in fundamental science led him to his first job as a PDF on theoretical chemistry. He won the AIME prize for graduate students in the field of metallurgy for his paper published in 1963. The subject of Professor Lu’s research always has been chemical kinetics. But, he has applied it to different topics relevant to ironmaking and steelmaking for the purpose of clarifying technical issues for better options to be defined by industry. Generous support from Canadian and American institutions, particularly Stelco Inc., enabled Professor Lu to succeed in bringing academics and industry closer by the establishment of the McMaster Symposium, Blast Furnace Ironmaking Course, and the Secondary Resources Study Group of Ontario. Fellow members of the Iron & Steel Society have recognized his contributions by presenting him with the T.L. Joseph Award, the Distinguished Member Award, and the Howe Memorial Lectureship of 1998. In July 1997, Professor Lu retired from regular professorship and now is a research professor. Without undergraduate teaching responsibilities, he has more time to intensify his efforts on “green technology.” Professor Lu is proud of his wife, Claudia, who married him in 1965 and is a successful businessperson, and their daughters, Olivia, a computer engineer, and Vanessa, a newspaper editor.     

Phase diagram calculations in teaching, research, and industry

I have a long-standing interest in alloy thermodynamics/phase diagrams and in utilizing the principles of this subject for materials research and engineering applications. At the same time, I also have a long association with ASM International as a member and a former Trustee of the Society. The Society’s initiative in promoting critical assessments of phase diagrams beginning in the late 1970s rekindled this field and stimulated further research, particularly in phase diagram calculations. Significant advancements have been made in phase diagram calculations using the Calphad approach since the late 1980s due primarily to the availability of inexpensive computers and robust software. In this article, I first present the use of computational thermodynamics including phase diagram calculation in teaching, next the use of calculated phase diagrams, particularly for multicomponent systems, for materials research/development, and manufacturing, and last describe some current research in advancing this methodology when the phases involve ordering with decreasing temperature. He received his BS from the University of California-Berkeley and his MS from the University of Washington-Seattle, both in Chemical Engineering, and his Ph.D. in Metallurgy from the University of California-Berkeley. After spending 4 years in industry, he joined the faculty of the College of Engineering and Applied Science, University of Wisconsin-Milwaukee, as Associate Professor in 1967 and was promoted to Professor in 1970. He served as the Chair of the Materials Department from 1971 to 1977 and then as the Associate Dean for Research in the Graduate School from 1978–1980. In 1980, he joined the faculty of the University of Wisconsin-Madison, in the Fall of 1980 as Professor, served as the Chair of the Department of Materials Science and Engineering from 1982 to 1991, and was named Wisconsin Distinguished Professor in 1988. He delivered the Edward DeMille Campbell Lecture at the Annual ASM International (ASM) Meeting, Pittsburgh, PA, on October 14, 2003. Professor Chang has a strong interest in research, teaching, and education. He is a Member of the National Academy of Engineering, a Foreign Member of the Chinese Academy of Sciences, and Fellow of ASM and the Minerals, Metals and Materials Society (TMS). He has focused his research on thermodynamic modeling/phase diagram calculation and in applying thermodynamics and kinetics to extraction/refining in his earlier career and then structural, electronic, and magnetic materials in bulk form as well as at the nanoscale. Among his recognitions are the Wisconsin Idea Fellow Award (UW System, 2004), a highly cited materials scientist covering the period 1981–1999 (ISHighlyCited, 2003), John Bardeen Award (TMS, 2000), Albert Sauveur Achievement Award (ASM, 1996). Champion H. Mathewson Medal (TMS, 1996), Extraction and Processing Lecturer Award (TMS, 1993), William Hume-Rothery Award (TMS, 1989), Belton Lecturer Award (CSIRO, Clayton, Victoria, Australia, 2000), Winchell Lecturer Award (Purdue University, 1999), Best Paper Award with Dr. W.-M. Huang (Alloy Phase Diagram International Commission or APDIC, 1999), Honorary Professorship (Northeast University, Shenyang, 1998-, Southeast University, Nanjing, 1997-, Central South University of Technology, Changsha, Hunan, 1996-, and University of Science and Technology Beijing, 1995-, all in the People’s Republic of China), Summer Faculty (Quantum Structure Research Initiative, Hewlett-Packard Laboratory, Palo Alto, CA, 1999). Honorary Chair Professor (National Tsing Hua University, Hsinchu, Taiwan, Republic of China, 2002–2005), Visiting Professorship (MIT, 1991 and Tohoku University, Sendai, 1987), Honorary Life Membership of Alpha Sigma Mu (1985), and Byron Bird Award (University of Wisconsin-Madison, 1978). He also received recognitions in teaching and education: an Outstanding Instructor Award (University of Wisconsin-Milwaukee, 1972), Educator Award (TMS, 1990), and Albert Easton White Distinguished Teacher Award (ASM, 1994). He served as a Trustee of ASM (1981–1984), as the 2000 President of TMS, and as the National President of Alpha Sigma Mu (1984).     

The interdisciplinary nature of hydrometallurgy

Hydrometallurgical extraction of metals is an important widely practiced technology in the metallurgical industry for treating both primary and secondary resources of valuable metals. Successful hydrometallurgical approaches to metal extraction require a full understanding of a wide spectrum of scientific and engineering principles in many disciplines. These include solution chemistry, electrochemistry, thermodynamics, kinetics, transport processes, and, frequently, biology. In this article, intricate relationships among various disciplines influencing hydrometallurgical extraction are reviewed and analyzed with pertinent examples. The effect of operating parameters on the overall extraction strategy are examined and discussed. The Extraction and Processing Lecturer Award honors an outstanding scientific leader in the field of nonferrous extractive metallurgy with an invitation to present a comprehensive lecture at the TMS Annual Meeting. Kenneth N. Han is the Regents Distinguished Professor and Douglas W. Fuerstenau Professor in the Department of Materials & Metallurgical Engineering at the South Dakota School of Mines and Technology (SDSM&T). He obtained his B.S. and M.S. degrees from Seoul National University (SNU), an M.S. from the University of Illinois, and a Ph.D. from the University of California, Berkeley. He was with the Department of Chemical Engineering, Monash University (Melbourne, Australia) from 1971 to 1980. In 1981, he joined SDSM&T. He was head of the Department of Metallurgical Engineering from 1987 to 1994 and dean of the College of Materials Science and Engineering from 1994 to 1999. His research interests include hydrometallurgy, interfacial phenomena, metallurgical kinetics, solution chemistry, fine particle recovery, and electrometallurgy. He has directed over 70 graduate students and postdoctorate researchers, published more than 150 papers in national and international journals, and presented more than 100 papers at international conferences. He is an author of ten monographs and holds eight patents in the area of extractive metallurgy. In 1987, he received the Presidential Professor Award from SDSM&T. In 1994, he received the Ernest L. Buckley Award, a South Dakota State Governor’s Award, for his industrial research efforts. He received the Milton E. Wadsworth Award and the Arthur F. Taggart Award from the Society of Mining, Metallurgical and Exploration in 1995. In 1997, he received the Distinguished Alumni Award from the College of Engineering of SNU. He became an SME Distinguished Member in 1998. In 1998, he was awarded the Excellence in Research by the SD Board of Regents. In 2000, he received the AIME Mineral Industry Education Award, and, in 2002, the Robert H. Richards Award from AIME. In 2003, he received the 2003 Extraction and Processing Distinguished Lecturer Award at the 132 TMS annual meeting in San Diego. He was inducted into the National Academy of Engineering in 1996. He is a foreign member of the National Academy of Engineering of Korea since 1998 and was inducted into the Korea Academy of Science and Technology in 1999.     

The science and technology of steelmaking—Measurements, models, and manufacturing

In our efforts to characterize and improve the performance of an existing steelmaking process or in our quest to generate useful knowledge as a basis for the development of new manufacturing routes, measurements and models should be considered as two interdependent requirements. Without measurements, our models are incomplete and unsatisfactory. Without models, we fail to realize, or perhaps even comprehend, the potential significance of our measurements. Sometimes in our enthusiasm, we construct sophisticated elegant models and forget the reality of the actual manufacturing process. In this computer age, we need to remember again the importance of observations and accurate measurements. In addition, as engineers and applied scientists, we have an obligation and a responsibility to facilitate the transfer of new knowledge into the realm of operating practice. During this process of generation, evaluation, and communication of new knowledge, the knowledge exchange step is perhaps the most difficult. In this context, the preeminent aim of collaborative activities between our educational institutions, industrial organizations, government funding agencies, and professional societies is to ensure the availability of high-quality people who not only understand the fundamental aspects and practical implications of their discipline, but also are fully equipped with the essential skills of communication that will enable them to participate throughout their career in this most challenging and satisfying activity, the science and technology of steelmaking. The Brimacombe Memorial Lectureship was established in 1999 by the Process Technology Division of the Iron & Steel Society to honor Dr. J. Keith Brimacombe’s outstanding accomplishments in the area of process metallurgy, his dedication to the steel industry, and his profound effect on people in the industry; and also to acquaint members, students, and engineers with the many exciting opportunities that exist in the area of process metallurgy and to inspire them to pursue careers in this field. Professor McLean obtained his degrees in Applied Chemistry and Metallurgy from the University of Glasgow and the Royal College of Science and Technology, now the University of Strathcylde. After 5 years with the Metallurgy and Materials Science Department at McMaster University in the mid-1960s, he moved to the Graham Research Laboratory of Jones and Laughlin Steel Corporation in Pittsburgh. He returned to Canada in 1970 and joined the Department of Metallurgy and Materials Science at the University of Toronto where he served as the American Iron and Steel Institute Distinguished Professor from 1982 through 1986 and as Department Chair from 1992 through 1997. He is an Adjunct Professor at Chiba Institute of Technology in Japan and holds the position of Invited Professor at Kyoto University. In 1985, he served as President of the Iron and Steel Society of AIME and in 1988 delivered the 65th Henry Marion Howe Memorial Lecture. He is an Honorary Member of AIME, the Iron & Steel Institute of Japan, and the Hungarian Mining & Metallurgical Society. He is a Fellow of the Royal Society of Canada and also several professional associations. He has received Honorary Doctorates from the University of Miskolc in Hungary and the University of Strathclyde in Scotland as well as awards from technical societies in Canada, the United States, the United Kingdom, and Japan for contributions to the science and technology of steel processing and for activities pertaining to metallurgical education. He has authored or co-authored about 300 publications and has served as a consultant to companies in North America and Europe and as a board member of several industrial organizations. He was appointed Professor Emeritus at the University of Toronto in 2002.     

Grain boundary cracking

A chronological summary is given of the various types of grain boundary fracture found in metals. In each case, there is an impurity that adsorbs at the new (fracture) surface being formed. For the case of Fe-P alloys, a quantitative argument can show that adsorption of phosphorous on the free surface greatly reduces the barrier to void nucleation compared to that in the absence of phosphorous. The same or larger reduction would appear for any other element, which adsorbs more strongly than phosphorous and displaces it at the surface. Such an argument is shown to explain a great many cases of dimpled grain boundary fracture in strong alloys undergoing creep or hydrogen attack. The reduction in surface energy can also lead to a smooth grain boundary fracture (no void nucleation), in which diffusion of solute to the new surface limits crack growth. Numerous examples of this are also discussed. Dr. Shewmon studied metallurgical engineering at the University of Illinois (B.S. 1952) and Carnegie Institute of Technology (Ph.D. 1955). His first job was at the Westinghouse Research Laboratory, where he studied thermal diffusion in alloys and surface diffusion. In 1958, he moved to the Carnegie Institute of Technology, where he served as a professor until 1967. The text “Diffusion in Solids” was published in 1963. An NSF Fellowship was used to study at Professor C. Wagner’s Max Planck Institute (Goettingen, Germany) in 1963. From 1968 to 1973, he was at Argonne National Laboratory, serving successively as Associate Director of the Metallurgy Division, Associate Director of the EBR-2 Project, and Director of the Materials Science Division. The text “Transformations in Metals” was published in 1969. Materials behavior in fast breeder reactors was the main theme of his work during this period. He was the director of the Division of Materials Research at the National Science Foundation from 1973 to 1975. From 1975 to 1993, he was Professor at Ohio State University in the Department of Metallurgical Engineering (later Materials Science and Engineering), serving as Chairman from 1975 to 1983. Research interests during this period were hard particle erosion and hydrogen-induced cracking of steel (“hydrogen attack”). From 1977 to 1993 he served on the Advisory Committee on Reactor Safety for the United States Nuclear Regulations Committee, serving as Chair for three of those years. Dr. Shewmon was elected to the National Academy of Engineering in 1979 and has been awarded the standing of Fellow in TMS, ASM, ANS, and AAAS. He has received several outstanding paper awards (Noble-AIME, Raymond—TMS, Mathewson—TMS, and Howe—ASM). He received the Distinguished Alumnus Award of the University of Illinois in 1981 and a Humboldt Foundation Senior Scientist Prize in 1984. The Edward DeMille Campbell Memorial Lecture was established in 1926 as an annual lecture in memory of and in recognition of the outstanding scientific contributions to the metallurgical profession by a distinguished educator who was blind for all but two years of his professional life. It recognizes demonstrated ability in metallurgical science and engineering. The Institute of Metals Lecture was established in 1921, at which time the Institute of Metals Division was the only professional division within the American Institute of Mining and Metallurgical Engineers. It has been given annually since 1922 by distinguished people from this country and abroad. Beginning in 1973 and thereafter, the person selected to deliver the lecture will be known as the “Institute of Metals Division Lecturer and R.F. Mehl Medalist” for that year.     

Grain boundary cracking

A chronological summary is given of the various types of grain boundary fracture found in metals. In each case, there is an impurity that adsorbs at the new (fracture) surface being formed. For the case of Fe-P alloys, a quantitative argument can show that adsorption of phosphorous on the free surface greatly reduces the barrier to void nucleation compared to that in the absence of phosphorous. The same or larger reduction would appear for any other element, which adsorbs more strongly than phosphorous and displaces it at the surface. Such an argument is shown to explain a great many cases of dimpled grain boundary fracture in strong alloys undergoing creep or hydrogen attack. The reduction in surface energy can also lead to a smooth grain boundary fracture (no void nucleation), in which diffusion of solute to the new surface limits crack growth. Numerous examples of this are also discussed. Dr. Shewmon studied metallurgical engineering at the University of Illinois (B.S. 1952) and Carnegie Institute of Technology (Ph.D. 1955). His first job was at the Westinghouse Research Laboratory, where he studied thermal diffusion in alloys and surface diffusion. In 1958, he moved to the Carnegie Institute of Technology, where he served as a professor until 1967. The text “Diffusion in Solids” was published in 1963. An NSF Fellowship was used to study at Professor C. Wagner’s Max Planck Institute (Goettingen, Germany) in 1963. From 1968 to 1973, he was at Argonne National Laboratory, serving successively as Associate Director of the Metallurgy Division, Associate Director of the EBR-2 Project, and Director of the Materials Science Division. The text “Transformations in Metals” was published in 1969. Materials behavior in fast breeder reactors was the main theme of his work during this period. He was the director of the Division of Materials Research at the National Science Foundation from 1973 to 1975. From 1975 to 1993, he was Professor at Ohio State University in the Department of Metallurgical Engineering (later Materials Science and Engineering), serving as Chairman from 1975 to 1983. Research interests during this period were hard particle erosion and hydrogen-induced cracking of steel (“hydrogen attack”). From 1977 to 1993 he served on the Advisory Committee on Reactor Safety for the United States Nuclear Regulations Committee, serving as Chair for three of those years. Dr. Shewmon was elected to the National Academy of Engineering in 1979 and has been awarded the standing of Fellow in TMS, ASM, ANS, and AAAS. He has received several outstanding paper awards (Noble-AIME, Raymond—TMS, Mathewson—TMS, and Howe—ASM). He received the Distinguished Alumnus Award of the University of Illinois in 1981 and a Humboldt Foundation Senior Scientist Prize in 1984. The Edward DeMille Campbell Memorial Lecture was established in 1926 as an annual lecture in memory of and in recognition of the outstanding scientific contributions to the metallurgical profession by a distinguished educator who was blind for all but two years of his professional life. It recognizes demonstrated ability in metallurgical science and engineering.     

The changing scene in steel

In the past thirty years the United States has moved from a position where it dominated world steel production to where it is now only one of the major world steel producers. The interplay of technology, economics and world politics which has brought this about will be reviewed, with particular emphasis on important technological changes which have occurred in the last three decades. To illustrate how research, development and application interacted to bring about change, specific examples will be given in ore reduction, continuous casting and high-strength steel products. The Edward DeMille Campbell Memorial Lecture was established in 1926 as an annual lecture in memory of and in recognition of the outstanding scientific contributions to the metallurgical profession by a distinguished educator who was blind for all but two years of his professional life. It recognizes demonstrated ability in metallurgical science and engineering. H. W. PAXTON is Vice President-Research of the United States Steel Corporation. He received a B.Sc. and M.Sc. in 1947 and 1948 from the University of Manchester and his Ph.D. in 1952 from the University of Birmingham. In 1953 he became Assistant Professor of Metallurgical Engineering at Carnegie Institute of Technology, subsequently Carnegie-Mellon University, and became Head of the Department of Metallurgy and Materials Science and Director of the Metals Research Laboratory of Carnegie-Mellon in 1966. He was Visiting Professor in Metallurgy and Materials Science at Imperial College, London, in 1962–63 and at the Massachusetts Institute of Technology in 1970, and served two years as the first Director, Division of Materials Research, National Science Foundation 1971–1973. He was a consultant to industry from 1953 to 1974 and has authored many technical papers, primarily in the field of physical metallurgy. He also co-authored a book,Alloying Elements in Steel, with the late Dr. E. C. Bain. Dr. Paxton received the Bradley Stoughton Award for young teachers of metallurgy in 1960. He is a member of the American Association for the Advancement of Science, Directors of Industrial Research, and the Industrial Research Institute; Fellow of the American Society for Metals and The Metallurgical Society of AIME; Past President of TMS; Vice President of the American Institute of Mining Metallurgical, and Petroleum Engineers; Past Chairman of the General Research committee of the American Iron and Steel Institute, and was elected to membership of the National Academy of Engineering on April 3, 1978.     

Drops and bubbles in extractive metallurgy

Drops and bubbles are of great importance to the extractive metallurgist in his attempts to speed up processes by the use of sprays, foams, and jets. In this lecture the ways in which bubbles bring about mass transfer in liquid metals and in slag metal reactions are described. The role of interfacial turbulence is considered together with the effects of bubble size and frequency and the properties of the slag and metal phases. Reactions between drops of metal and flowing gases are analyzed in terms of mass transfer in the reacting phases and of chemical steps at the interface. Recent results obtained on reactions involving metal drops falling through liquids are considered in relation to mass transfer models in which internal circulation plays an important part. The work described reports only one facet of the rapidly developing subject of Process Engineering which ought now to feature prominently in metalurgical education. Dr. F. DENYS RICHARDSON. Professor of Extraction Metallurgy. Department of Metallurgy, Royal School of Mines. Imperial College of Science and Technology, London, England, graduated in chemistry at University College, London, in 1933, and obtained a Ph.D. in physical chemistry in 1936. From 1937 to 1939 he was Commonwealth Fund Fellow at the University of Princeton. From 1946 to 1950 he worked as superintendent chemist at BISRA, building up the work of the chemistry department. He went to Imperial College in 1950 to found the Nuffield Research Group in Extraction Metallurgy and advance the study of chemical metallurgy at high temperatures. He received awards in recognition of his work on the thermodynamic properties of high-temperature systems with special reference to iron- and steelmaking and for his work on high-temperature chemical metallurgy. He was appointed Professor of Extraction Metallurgy at Imperial College in 1957, his objectives there being to establish the department as a research center for chemical and process engineering metallurgy, and to develop a metallurgy course in which these subjects receive as much attention as physical metallurgy. In 1963 he was elected a Fellow of the Metallurgical Society of the AIME, and in 1964 he gave the AIME Howe Memorial Lecture. Professor Richardson delivered the Hatfield Memorial Lecture in 1964, the May Lecture of the Institute of Metals in 1965, and the Wernher Memorial Lecture of The Institution of Mining and Metallurgy in 1967. He was elected a Member of Council of the Iron and Steel Institute in 1967, having been an Honorary Member since 1962. In 1968 he became a Vice-President of the Institution of Mining and Metallurgy. In that year he was also elected a Fellow of the Royal Society and awarded the Bessemer Gold Medal of the Iron and Steel Institute, both honors for his contribution to the understanding of the thermodynamics and kinetics of metallurgical processes. In 1970 the honorary degree of Doktor-Ingenieur was conferred on him by the Technische Hochschale, Aachen. The 1971 Extractive Metallurgy Division Lecture, “Drops and Bubbles in Extractive Metallurgy.” was delivered on Wedresday, March 3, 1971.     

Deformation and fracture in martensitic carbon steels tempered at low temperatures

This article reviews the strengthening and fracture mechanisms that operate in carbon and low-alloy carbon steels with martensitic microstructures tempered at low temperatures, between 150 °C and 200 °C. The carbon-dependent strength of low-temperature-tempered (LTT) martensite is shown to be a function of the dynamic strain hardening of the dislocation and transition carbide substructure of martensite crystals. In steels containing up to 0.5 mass pct carbon, fracture occurs by ductile mechanisms of microvoid formation at dispersions of second-phase particles in the matrix of the strain-hardened tempered martensite. Steels containing more than 0.5 mass pct carbon with LTT martensitic microstructures are highly susceptible to brittle intergranular fracture at prior austenite grain boundaries. The mechanisms of the intergranular fracture are discussed, and approaches that have evolved to minimize such fracture and to utilize the high strength of high-carbon hardened steels are described. The Edward DeMille Campbell Memorial Lecture was established in 1926 as an annual lecture in memory of and in recognition of the outstanding scientific contributions to the metallurgical profession by a distinguished educator who was blind for all but two years of his professional life. It recognizes demonstrated ability in metallurgical science and engineering. Dr. George Krauss is currently University Emeritus Professor at the Colorado School of Mines. He received the B.S. in Metallurgical Engineering from Lehigh University in 1955 and the M.S. and Sc.D. degrees in Metallurgy from the Massachusetts Institute of Technology in 1958 and 1961, respectively, after working at the Superior Tube Company as a Development Engineer in 1956. In 1962–63, he was an NSF Postdoctoral Fellow at the Max-Planck-Institut für Eisenforshung (Düsseldorf, Germany). He served at Lehigh University as Assistant Professor, Associate Professor, and Professor of Metallurgy and Materials Science from 1963 to 1975 and, in 1975, joined the faculty of the Colorado School of Mines as the AMAX Professor of Physical Metallurgy. He was the John Henry Moore Professor of Metallurgical and Materials Engineering at the time of his retirement from the Colorado School of Mines in 1997. In 1984, Dr. Krauss was a principal in the establishment of the Advanced Steel Processing and Products Research Center, an NSF industry-university cooperative research center at the Colorado School of Mines, and served as its first director until 1993. He has authored the book Steels: Heat Treatment and Processing Principles, ASM International, 1990, coauthored the book Tool Steels, Fifth Edition, ASM International, 1998, and edited or coedited several conference volumes on topics including tempering of steel, carburizing, zinc-based coatings on steel, and microalloyed forging steels. He has published over 280 papers and lectured widely at technical conferences, universities, corporations, and ASM chapters, including a number of keynote, invited, and honorary lectures. Dr. Krauss has served as the President of the International Federation of Heat Treatment and Surface Modification, 1989–91, and as President of ASM International, 1996–97. He is a Fellow of ASM International and has received the Adolf Martens Medal of the German Society for Heat Treatment and Materials Technology, the Charles S. Barrett Silver Medal of the Rocky Mountain Chapter ASM, the George Brown Gold Medal of the Colorado School of Mines, and several other professional and teaching awards, including the ASM Albert Easton White Distinguished Teacher Award in 1999. He is an Honorary Member of the Iron and Steel Institute of Japan and a Distinguished Member of the Iron and Steel Society of AIME.     

Computer simulation of solidification processes—The evolution of a technology

The historical development of solidification modeling is traced, as applied to solidification processing. Clearly, the growth of this technology followed the computer explosion, particularly with regard to hardware. However, universities and government laboratories made substantial contributions in the software area, particularly in removing roadblocks to the further development of the technology and by creative examples. The commercial software houses have utilized these leading-edge developments, a practice continued and expanding today. Heat-transfer analyses by computer were initiated by utilizing the analog computer, which appeared to be a competing technology, but by the early 1960s, the digital computer had become the winner in larger-scale computation. A number of benchmark achievements followed over the next several decades. The evolution of this technology is documented, including predictions of solidification microstructure and resulting material properties. Future developments are projected. This lecture was presented to honor Edward DeMille Campbell (University of Michigan, Class of 1886), born in 1863, who was appointed Assistant Professor of Metallurgy in 1890. Dr. Campbell brought a strong interest in the study of the constitution of metals and alloys to the University of Michigan. In 1892, during a study of the composition of steel, he lost his eyesight in a laboratory explosion. Within five days, he returned to the University, and resumed his teaching and research. Over the next 30 years, he published 72 research papers, and developed a laboratory course in metallography. In 1924, working under the direction of Professor Campbell, William Fink discovered a new, tetragonal form of iron (martensite) in the first significant application of a new tool, X-ray diffraction, to physical metallurgy. It was these experiments that established the beginning of a strong tradition in physical metallurgy at the University of Michigan. In 1898, Campbell led the effort to establish Chemical Engineering at Michigan, becoming Professor of Chemical Engineering and Analytical Chemistry in 1902. In 1914, Campbell was appointed Director of the University’s Chemical Laboratory and Professor of Chemistry. Following his death in 1925, the American Society for Metals established this annual award in his name. The Edward DeMille Campbell Memorial Lecture was established in 1926 as an annual lecture in memory of and in recognition of the outstanding scientific contributions to the metallurgical profession by a distinguished educator who was blind for all but two years of his professional life. It recognizes demonstrated ability in metallurgical science and engineering. Robert D. Pehlke studied at the University of Michigan, B.S.E. (Met. Eng.) 1955, Massachusetts Institute of Technology, S.M. (Met.) 1958, and Sc.D. (Met.) 1960, and at the Technical Institute, Aachen, as a Fulbright Fellow, 1956–57. He joined the faculty of the University of Michigan as Assistant Professor in February 1960, and was appointed Associate Professor in June 1963 and full Professor in June 1968. In May 1973, he was named Chairman of the Department of Materials and Metallurgical Engineering. In June 1978 and 1983, he was reappointed Department Chairman and served until June 1984. In 1994, he was Visiting Professor at Tohoku University (Sendai, Japan). He is a member of AIME and ASM, and has served on numerous divisional and award committees within these societies. He has served on the Technical Divisions Board (1982–84), as Secretary of the ASM Academy for Metals and Materials Committee, and in 1976 was named a Fellow of the Society. In 1964, he co-edited the ASM seminar volume on Computers in Metallurgy. He has served as Chairman of the Process Technology Division and as a Director of the ISS-AIME. In 1980, he was named a Distinguished Life Member of the ISS. In 1976, he received the Science Award Gold Medal of the Extractive Metallurgy Division of TMS-AIME. In 1983, he was named a Fellow of TMS. He was chairman of the former AIME-ISS Division Publications Committee. He served as chairman of the Editorial Board for the AIME Monograph Series on Oxygen Steelmaking. In 1980, he presented the Howe Memorial Lecture on “Steelmaking—The Jet Age.” In 1991–92, he was the Krumb Lecturer of the Metallurgical Society. In 1980, he was named a Case Institute Centennial Scholar and the Van Horn Distinguished Lecturer at Case Western Reserve University. He has lectured widely internationally, and at technical conferences, universities, corporations, and technical society chapters, including presenting a number of keynote, invited, and honorary lectures. He was National President of Alpha Sigma Mu and a member of Tau Beta Pi, Sigma Xi, and the New York Academy of Sciences. He is also a member of the American Society for Engineering Education and the American Foundry Society. He has held memberships in the Iron and Steel Institute of London, the Iron and Steel Institute of Japan, and the Verein Deutscher Eisenhuttenleute. He is a registered professional engineer in the State of Michigan. Dr. Pehlke has served as Foundry Educational Foundation Professor at The University of Michigan for 17 years. Professor Pehlke has authored or co-authored over 300 publications, including editing, authoring, or co-authoring 11 books. His text Unit Processes of Extractive Metallurgy has been widely used throughout the world. He co-authored Continuous Casting—Design and Operations, which is Volume 4 of the ISS-AIME series. He has won seven American Foundry Society Best Paper awards. In 1963, Dr. Pehlke published an ASM pioneering paper first describing computer modeling of continuous casting of steel. In 1964, he continued this work in conjunction with McLouth Steel Corporation, which had just installed the first slab casting machine for steel in the United States. In 1968, he, with the support of the Heat Transfer Committee of the American Foundry Society, initiated the first university research program in North America on computer modeling of the solidification of shaped castings. His early professional employment included three summers each with General Motors Research Laboratories and the Ford Scientific Laboratory. He has consulted extensively on a wide range of metallurgical subjects, principally with ferrous and nonferrous metal producers and their suppliers. His research has covered a broad range of metallurgical topics with an emphasis on high-temperature physical chemistry of metallurgical systems, modeling of solidification of metals, and computer applications in metallurgy.     

Computer simulation of solidification processes—The evolution of a technology

The historical development of solidification modeling is traced, as applied to solidification processing. Clearly, the growth of this technology followed the computer explosion, particularly with regard to hardware. However, universities and government laboratories made substantial contributions in the software area, particularly in removing roadblocks to the further development of the technology and by creative examples. The commercial software houses have utilized these leading-edge developments, a practice continued and expanding today. Heat-transfer analyses by computer were initiated by utilizing the analog computer, which appeared to be a competing technology, but by the early 1960s, the digital computer had become the winner in larger-scale computation. A number of benchmark achievements followed over the next several decades. The evolution of this technology is documented, including predictions of solidification microstructure and resulting material properties. Future developments are projected. This lecture was presented to honor Edward DeMille Campbell (University of Michigan, Class of 1886), born in 1863, who was appointed Assistant Professor of Metallurgy in 1890. Dr. Campbell brought a strong interest in the study of the constitution of metals and alloys to the University of Michigan. In 1892, during a study of the composition of steel, he lost his eyesight in a laboratory explosion. Within five days, he returned to the University, and resumed his teaching and research. Over the next 30 years, he published 72 research papers, and developed a laboratory course in metallography. In 1924, working under the direction of Professor Campbell, William Fink discovered a new, tetragonal form of iron (martensite) in the first significant application of a new tool, X-ray diffraction, to physical metallurgy. It was these experiments that established the beginning of a strong tradition in physical metallurgy at the University of Michigan. In 1898, Campbell led the effort to establish Chemical Engineering at Michigan, becoming Professor of Chemical Engineering and Analytical Chemistry in 1902. In 1914, Campbell was appointed Director of the University’s Chemical Laboratory and Professor of Chemistry. Following his death in 1925, the American Society for Metals established this annual award in his name. The Edward DeMille Campbell Memorial Lecture was established in 1926 as an annual lecture in memory of and in recognition of the outstanding scientific contributions to the metallurgical profession by a distinguished educator who was blind for all but two years of his professional life. It recognizes demonstrated ability in metallurgical science and engineering. Robert D. Pehlke studied at the University of Michigan, B.S.E. (Met. Eng.) 1955, Massachusetts Institute of Technology, S.M. (Met.) 1958, and Sc.D. (Met.) 1960, and at the Technical Institute, Aachen, as a Fulbright Fellow, 1956–57. He joined the faculty of the University of Michigan as Assistant Professor in February 1960, and was appointed Associate Professor in June 1963 and full Professor in June 1968. In May 1973, he was named Chairman of the Department of Materials and Metallurgical Engineering. In June 1978 and 1983, he was reappointed Department Chairman and served until June 1984. In 1994, he was Visiting Professor at Tohoku University (Sendai, Japan). He is a member of AIME and ASM, and has served on numerous divisional and award committees within these societies. He has served on the Technical Divisions Board (1982–84), as Secretary of the ASM Academy for Metals and Materials Committee, and in 1976 was named a Fellow of the Society. In 1964, he co-edited the ASM seminar volume on Computers in Metallurgy. He has served as Chairman of the Process Technology Division and as a Director of the ISS-AIME. In 1980, he was named a Distinguished Life Member of the ISS. In 1976, he received the Science Award Gold Medal of the Extractive Metallurgy Division of TMS-AIME. In 1983, he was named a Fellow of TMS. He was chairman of the former AIME-ISS Division Publications Committee. He served as chairman of the Editorial Board for the AIME Monograph Series on Oxygen Steelmaking. In 1980, he presented the Howe Memorial Lecture on “Steelmaking—The Jet Age.” In 1991–92, he was the Krumb Lecturer of the Metallurgical Society. In 1980, he was named a Case Institute Centennial Scholar and the Van Horn Distinguished Lecturer at Case Western Reserve University. He has lectured widely internationally, and at technical conferences, universities, corporations, and technical society chapters, including presenting a number of keynote, invited, and honorary lectures. He was National President of Alpha Sigma Mu and a member of Tau Beta Pi, Sigma Xi, and the New York Academy of Sciences. He is also a member of the American Society for Engineering Education and the American Foundry Society. He has held memberships in the Iron and Steel Institute of London, the Iron and Steel Institute of Japan, and the Verein Deutscher Eisenhuttenleute. He is a registered professional engineer in the State of Michigan. Dr. Pehlke has served as Foundry Educational Foundation Professor at The University of Michigan for 17 years. Professor Pehlke has authored or co-authored over 300 publications, including editing, authoring, or co-authoring 11 books. His text Unit Processes of Extractive Metallurgy has been widely used throughout the world. He co-authored Continuous Casting—Design and Operations, which is Volume 4 of the ISS-AIME series. He has won seven American Foundry Society Best Paper awards. In 1963, Dr. Pehlke published an ASM pioneering paper first describing computer modeling of continuous casting of steel. In 1964, he continued this work in conjunction with McLouth Steel Corporation, which had just installed the first slab casting machine for steel in the United States. In 1968, he, with the support of the Heat Transfer Committee of the American Foundry Society, initiated the first university research program in North America on computer modeling of the solidification of shaped castings. His early professional employment included three summers each with General Motors Research Laboratories and the Ford Scientific Laboratory. He has consulted extensively on a wide range of metallurgical subjects, principally with ferrous and nonferrous metal producers and their suppliers. His research has covered a broad range of metallurgical topics with an emphasis on high-temperature physical chemistry of metallurgical systems, modeling of solidification of metals, and computer applications in metallurgy.     

Deformation and fracture in martensitic carbon steels tempered at low temperatures

This article reviews the strengthening and fracture mechanisms that operate in carbon and low-alloy carbon steels with martensitic microstructures tempered at low temperatures, between 150 °C and 200 °C. The carbon-dependent strength of low-temperature-tempered (LTT) martensite is shown to be a function of the dynamic strain hardening of the dislocation and transition carbide substructure of martensite crystals. In steels containing up to 0.5 mass pct carbon, fracture occurs by ductile mechanisms of microvoid formation at dispersions of second-phase particles in the matrix of the strain-hardened tempered martensite. Steels containing more than 0.5 mass pct carbon with LTT martensitic microstructures are highly susceptible to brittle intergranular fracture at prior austenite grain boundaries. The mechanisms of the intergranular fracture are discussed, and approaches that have evolved to minimize such fracture and to utilize the high strength of high-carbon hardened steels are described. The Edward DeMille Campbell Memorial Lecture was established in 1926 as an annual lecture in memory of and in recognition of the outstanding scientific contributions to the metallurgical profession by a distinguished educator who was blind for all but two years of his professional life. It recognizes demonstrated ability in metallurgical science and engineering. Dr. George Krauss is currently University Emeritus Professor at the Colorado School of Mines. He received the B.S. in Metallurgical Engineering from Lehigh University in 1955 and the M.S. and Sc.D. degrees in Metallurgy from the Massachusetts Institute of Technology in 1958 and 1961, respectively, after working at the Superior Tube Company as a Development Engineer in 1956. In 1962–63, he was an NSF Postdoctoral Fellow at the Max-Planck-Institut für Eisenforshung (Düsseldorf, Germany). He served at Lehigh University as Assistant Professor, Associate Professor, and Professor of Metallurgy and Materials Science from 1963 to 1975 and, in 1975, joined the faculty of the Colorado School of Mines as the AMAX Professor of Physical Metallurgy. He was the John Henry Moore Professor of Metallurgical and Materials Engineering at the time of his retirement from the Colorado School of Mines in 1997. In 1984, Dr. Krauss was a principal in the establishment of the Advanced Steel Processing and Products Research Center, an NSF industry-university cooperative research center at the Colorado School of Mines, and served as its first director until 1993. He has authored the book Steels: Heat Treatment and Processing Principles, ASM International, 1990, coauthored the book Tool Steels, Fifth Edition, ASM International, 1998, and edited or coedited several conference volumes on topics including tempering of steel, carburizing, zinc-based coatings on steel, and microalloyed forging steels. He has published over 280 papers and lectured widely at technical conferences, universities, corporations, and ASM chapters, including a number of keynote, invited, and honorary lectures. Dr. Krauss has served as the President of the International Federation of Heat Treatment and Surface Modification, 1989–91, and as President of ASM International, 1996–97. He is a Fellow of ASM International and has received the Adolf Martens Medal of the German Society for Heat Treatment and Materials Technology, the Charles S. Barrett Silver Medal of the Rocky Mountain Chapter ASM, the George Brown Gold Medal of the Colorado School of Mines, and several other professional and teaching awards, including the ASM Albert Easton White Distinguished Teacher Award in 1999. He is an Honorary Member of the Iron and Steel Institute of Japan and a Distinguished Member of the Iron and Steel Society of AIME.     

Future steelmaking technologies and the role of basic research

The steel industry is going through a technological revolution that will not only change how steel is produced but also the entire structure of the industry. The drivers for the new or improved technologies, including reduction in capital requirements, possible shortages in raw materials such as coke and low residual scrap, environmental concerns, and customer demands are briefly examined. The required response of the industry to these drivers will be new processes such as direct ironmaking, near net shape casting, and those to improve charge materials to the electric arc furnace (EAF). The know-how for these process improvoeemnts and revolutionary technologies can be purchased, if it exists. However, since the U.S. industry has a unique set of drivers, it may be necessary to develop many of the new technologies through its own research and development. The current status of research and developoment in the United States and selected international producers was examined. As expected, it was found that the industry’s research capabilities have been greatly reduced. Furthermore, less than half of the companies that identified a given technology as critical have significant research and development programs addressing the technology. It is clear that, in many cases, these technologies must be developed collaboratively using all of the intellectual resources available, including universities. Much of the basic process understanding and data for optimization can be obtained from basic research, which is highly focused on the requirements of the new process, thus eliminating some expensive pilot plant trials. Examples of how basic research aided in process improvements in the past are given. The examples include demonstrating how fundamentals of reaction kinetics, improved nitrogen control, and thermodynamics of systems helped reduce nozzle clogging and how fluid flow studies reduced defects in casting. However, in general, basic research did not play a major role in processes previously developed but helped our understanding and aided optimization. To have a major impact, basic research must be focused and be an integral part of any new process development. An example where this has been done successfully is the AISI Direct Ironmaking and Waste Oxide Recycle projects, in which fundamental studies on reduction, slag foaming, and postcombustion reactions have led to process understanding, control, and optimization. Industry leaders recognize the value and need for basic research but insist it be truly relevant and done with industry input. From these examples, the lessons learned on how to make basic research more effective are discussed. Professor Richard J. Fruehan received his B.S. and Ph.D. degrees from the University of Pennsylvania in 1963 and 1966, respectively. He was an NSF postdoctoral scholar at Imperial College, University of London, from 1966 to 1967. He then was on the staff of the United States Steel Laboratory until he joined the faculty of Carnegie Mellon University as a Professor in 1980. Dr. Fruehan organized the Center for Iron and Steelmaking Research, an NSF Industry/University Cooperative Research Center, and is currently the director. The Center currently has 24 industrial company members, including those in the United States, Europe, Asia, South Africa, and South America. Dr. Fruehan has authored over 150 papers, two books, and co-authored two additional books and is the holder of five patents. He has received several awards for his publications, including the 1970 and 1982 Hunt Medal (AIME), the 1982 and 1991 John Chipman Medal (AIME), the 1989 Mathewson Gold Medal (TMS-AIME), the 1993 Albert Sauveur Award (ASM INTERNATIONAL), the 1976 Gilcrist Medal (Metals Society, London), and the 1996 Howe Memorial Lecture (ISS-AIME); he also received an IR100 Award for the invention of the oxygen sensor. In 1985, he was elected a distinguished member of the Iron and Steel Society. He served as president of the Iron and Steel Society of AIME from 1990 to 1991. In 1997, he was appointed the U.S. Steel Professor of the Materials Science and Engineering Department, Carnegie Mellon University.     

Metal extraction from ores by heap leaching

Heap leaching low-grade ores has become a major contributor to the extraction of economically important metals, notably copper and gold. The state-of-the-art in heap leaching is reviewed with emphasis on process engineering. Rock leaching, including rock pore diffusion and mineral kinetics, solution flow, and retention in ore heaps during percolation leaching, and bio-oxidation of sulfidic ores are covered. Oxygen transport into heaps by gaseous diffusion, natural convection, and forced air ventilation is discussed. Strategies for optimizing heap leaching include ore crushing, ore agglomeration, low-cost air ventilation of sulfide ore heaps undergoing bio-oxidation using fans, and the use of aggregate metal extraction rate constants in making metallurgical business decisions about heap leaching. The Extraction and Processing Lecturer Award honors an outstanding scientific leader in the field of nonferrous extractive metallurgy with an invitation to present a comprehensive lecture at the TMS Annual Meeting. Robert W. Bartlett, presently dean of the College of Mines and Earth Resources and professor of metallurgical engineering at the University of Idaho, has spent half of his career in industry, Anaconda, ARCO, and Kennecott, and half in academia, Stanford and Idaho. He earned his degrees at the University of Utah. His lecture is based on research in industry and at the University of Idaho. Dr. Bartlett has been a member of TMS for over 40 years and was president in 1989. Earlier, he was a member of the TMS Board of Directors representing, for 3 years, what is now the Extraction and Processing Division. Dr. Bartlett consults primarily on processing in the mining and metals industries. He is a recipient of the TMS Extraction and Processing Technology Award, the Turner Award of the Electrochemical Society, the Wadsworth Award of the Society of Mining, Metallurgy and Exploration, and the McConnell Award of AIME. He is a member of the National Academy of Engineering.     

Dalbir Bindra: 1922-1980.

Presents an obituary for Dalbir Bindra, the quintessence of the rational man. From an early age he dedicated himself with uncommon objectivity and analytic skill to psychology as science. For him the important problem in psychology was the concomitance of neural and behavioural events. This classic problem has fascinated some of the great minds in the history of thought. With courage, persistence, optimism, and singleness of purpose, he applied all his theoretical and experimental skills to this problem. His faith in science was unusually strong. Dalbir Bindra throughout his career was active in psychology in Canada and played an important role in its growth. One of his interests was financial support for research in psychology. He wrote reports and published papers on this topic. From 1962-68 he was chairperson of the Associate Committee on Experimental Psychology of the National Research Council of Canada. He was President of the Canadian Psychological Association in 1958-59. He was awarded the Canadian Centennial Medal in 1967. He was a Fellow of the Canadian and American Psychological Associations. In 1973 he was elected Fellow of the Royal Society of Canada, one of the very few psychologists in Canada to be so honored. (PsycINFO Database Record (c) 2010 APA, all rights reserved)